101 Harley-Davidson Evolution
Performance Projects (2nd Edition)
Motorbooks.
Author: Kip Woodring
Photographer: Kenna Love
Paperback, 256 Pages
Easy to follow step-by-step instructions with hundreds of color illustrations.
Keep a veteran mechanic at hand with this updated version of the best-selling manual for Harley-Davidson owners who want to hop up their machines. Created with the weekend mechanic in mind, this comprehensive, illustrated guide clearly and concisely outlines 101 projects that will improve the power, handling, and ride of Evolution-engined Harley-Davidson motorcycles. Drawing on years of hopping up and living with Evo-engined Big Twins and Sportsters, author and Harley-Davidson technician Kip Woodring provides step-by-step instructions for projects ranging from the basics of simple maintenance to the finer points of altering gearing, upgrading ignition, and making the changes that make a bike unique.
About the Author
Kip Woodring, the author of MBI's Harley-Davidson Sportster/Buell Engine Hop-Up Guide, has been writing for Harley-Davidson publications for more than 20 years. A certified mechanic, he lives in Scotts Valley, CA.
CONTENTS
ACKNOWLEDGMENTS
INTRODUCTION
Understanding the Information Boxes
ONE: BASICS
The Lowdown on Replacement Parts
Tools
Vehicle Identification Numbers WIN)
TWO: SIMPLE MAINTENANCE
Project 1: Performing the 10,000-Mile Service
Project 2: Lubing Cables
Project 3: Changing Engine Oil
Project 4: Changing Transmission and Primary Fluid
Project 5: Servicing Air Cleaner
Project 6: Choosing, Reading, and Replacing Spark Plugs
Project 7: Checking and Tensioning Your Drive Belt
Project 8: Replacing Brake Pads
Project 9: Timing Your Engine
Project 10: Adjusting Your Clutch
THREE: FUEL AND EXHAUST
Project 11: Installing a High-Performance Air Cleaner
Project 12: Rejetting for Altitude
Project 13: Tuning Your CV Carb
Project 14: Choosing a Jet Kit
Project 15: Installing a CV Jet Kit
Project 16: Swapping Garbs
Project 17: Choosing a High-Performance Exhaust
Project 18: Installing High-Flow Petcocks
Project 19: Adding an EFI Tuning Module
Project 20: Troubleshooting Fuel Injection
Project 21: Hot-Rodding Fuel Injection
FOUR: SUSPENSION AND CHASSIS
Project 22: Fixing Clunking Wide Glide Forks
Project 23: Installing a Cartridge-Fork Emulator Valve
Project 24: Retrofitting 1200S Cartridge Forks and Shocks
Project 25: Lowering Forks
Project 26: Lowering the Softail Rear
Project 27: Lowering Twin-Shock Rear Ends
Project 28: Installing Air Shock Rear Suspension on a Softail
Project 29: Taming Vibration—Servicing Rubber Engine Mounts
Project 30: Installing a Torque Arm or Race Brace
FIVE: TIRES, WHEELS, AND BRAKES
Project 31: Installing Wide Tires and Thin Belts
Project 32: Building and Maintaining Wire Wheels
Project 33: Servicing Your Brakes
Project 34: Upgrading Brake Discs|
Project 35: Installing Multipiston Brake Calipers
Project 36: Upgrading Softail Brakes
SIX: ENGINE
Project 37 Finding Your Build Date
Project 38: Keeping Excess Oil Out of Your Air Cleaner
Project 39: Blueprinting Your Engine
Project 40: Breaking in a New Engine
Project 41: Setting Cam and Ignition Timing
Project 42: Increasing Compression Ratio
Project 43: Fixing Base Gasket Leaks
Project 44: Checking Cylinders
Project 45: Choosing High-Performance Heads for Your Sponst
Project 46: Choosing High-Performance Heads for Your Big Twin
Project 47: Sealing Your Rocker Boxes
Project 48: Installing Roller Rocker Arms and Adjustable Pushrods
Project 49: Converting Sportster 883s to 1200s (and more)
Project 50: Choosing Aftermarket Camshafts
Project 51: Installing an Aftermarket Camshaft
Project 52: Replacing 1992 and Later Big Twin Cam Bearings
Project 53: Balancing Your Engine
Project 54: Crank Assembly Repair
Project 55: Replacing Crankcases
Project 56: Aftermarket XL Crankcases
Project 57: Replacing Noisy Pinion Gears on Big Twins
Project 58: Selecting High-Performance Pistons
Project 59: Dyno Tuning Your Engine
Project 60: Using Desktop Dynos
SEVEN: LUBRICATION
Project 61: Installing an Oil Cooler
Project 62: Fixing Your Sportster's Oil Tank
Project 63: Upgrading Your Sportster's Oil Pump
Project 64: Upgrading Your Big Twin's Oil Pump
Project 65: Keeping Your Oil Particle-Free
EIGHT: DRIVETRAIN
Project 66: Updating the 1984 1/2-1989 Big Twin Clutch
Project 67: Updating the 1984-1986 Big Twin Main Drive Gear
Project 68: Installing a Pro-Clutch
Project 69: Improving the Four-Speed Sportster Clutch
Project 70: Improving the Five-Speed Sportster Clutch
Project 71: Fitting a Primary Chain Tensioner
Project 72: Installing Fluid Balance Masters
Project 73: Updating Five-Speed Big Twin Belts and Pulleys
Project 74: Installing a Belt Primary Drive
NINE: TRANSMISSION
Project 75: Fixing Hard-Shifting Sportster Four Speeds
Project 76: Altering Final Gearing
Project 77: Fixing Sloppy Sportster Five-Speed Shifting
Project 78: Fixing Tranny Mainshaft Leaks on Your Four-Speed Big Twin
Project 79: Installing a Six-Speed Gear Set
TEN: ELECTRICAL SYSTEMS
Project 80: The Truth about Gauges
Project 81: Choosing High-Performance Plug Wires
Project 82: Servicing Your Battery
Project 83: Installing a High-Performance Starter on Big Twins
Project 84: Upgrading Your Charging System
Project 85: Selecting a High-Performance Factory Ignition Module
Project 86: Choosing and Installing an Aftermarket Ignition
Project 87: Optimizing Your VOES
Project 88: Troubleshooting Electrics
Project 89: Mapping Your Ignition Curve
ELEVEN: PERSONAL TOUCHES
Project 90: Clean and Shine
Project 91: Swapping Turn Signals
Project 92: Swapping Taillights
Project 93: Choosing Sissybars and Racks
Project 94: Choosing a Crate Motor
Project 95: Paint Repair
Project 96: Installing Chrome Handlebar Controls
Project 97: Changing Handlebars
Project 98: Hiding Handlebar Wiring
Project 99: Mounting Forward Controls on Your Big Twin
Project 100: Installing Rearsets and Forward Controls on Your Sportster
Project 101: Applying Coatings
APPENDIX A
APPENDIX B
SOURCES
INDEX
